Power layer generation of inverter gate drive signals

ABSTRACT

Techniques include systems and methods of synchronizing multiple parallel inverters in a power converter system. In one embodiment, control circuitry is connected to a power layer interface circuitry at each of the parallel inverters, via an optical fiber interface. The system is synchronized by transmitting a synchronizing pulse to each of the inverters. Depending on the operational mode of the system, different data exchanges may occur in response to the pulse. In an off mode, power up and power down data may be exchanged between the control circuitry and the inverters. In an initiating mode, identification data may be transmitted from the inverters to the control circuitry. In an active mode, control data may be sent from the control circuitry to the inverters. In some embodiments, the inverters also transmit feedback data and/or acknowledgement signals to the control circuitry. Power layer circuitry of the inverter adjusts a local clock based upon sampled data from the control circuitry to maintain synchronicity of the inverters between synchronization pulses.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional Application of U.S. patent applicationSer. No. 12/838,255 entitled “Power Layer Generation of Inverter GateDrive Signals,” filed Jul. 16, 2010, which is herein incorporated byreference.

BACKGROUND

The invention relates generally to the field of power conversion devicesand more particularly to inverters and their control.

Large number of topographies and types of power conversion circuits areknown and are in use. Many of these circuits rely upon invertertopologies for converting direct current (DC) power to control frequencyalternating current (AC) power. In many topologies a rectifier or otherconverter is provided to receive incoming AC power, typically from thegrid, and to convert the AC power to DC power that is applied to a DCbus used to feed the inverter circuitry. Such topologies are used in avariety of applications, such as for controlling the speed and operatingcharacteristics of motors.

Motor drives utilizing inverter topologies often employ a singleconverter and single inverter coupled to one another by a single DC bus.Conventional inverters are formed by solid state switches provided inpairs and alternately switched between conducting and non-conductingstates to provide desired output waveforms, typically of controlledfrequency. Such topologies are adequate for many smaller applications,and may vary in size depending upon the power rating, frame size,voltage, and other specifications of the driven motor. However, forlarger motors the components of such drives become proportionally largeand expensive. It becomes attractive, then, to use alternativetopologies in which multiple inverters are provided in parallel, withtheir outputs being joined to provide a common AC output to a load.

Such parallel inverter applications pose unique difficulties. Forexample, because the outputs of the inverters are essentially shorted toone another, various magnetic structures may be required to preventcirculating currents from being established due to mismatched timing inthe switching of the power electronic switches in the inverters. Forexample, if switches in a first inverter are switched in a manner thatis not sufficiently synchronized with switches of a parallel inverter,output power can be allowed to re-enter one or the other of theinverters due to the conductive states of the switches. Because theswitching frequencies of such inverter components is quite high, a highdegree of precision will be required to prevent such circulatingcurrents absent magnetic structures of the type used in the art.Furthermore, techniques for maintaining synchronous operation ofparallel inverters may be more efficiently and accurately conducted inparallel. Sufficient topologies for precise switching and parallelsynchronizing techniques have yet to be proposed.

BRIEF DESCRIPTION

The present invention provides techniques for synchronizing invertersdesigned to respond to such needs. In accordance with one aspect of thepresent technique, a system is provided for controlling the operation ofmultiple power inverters connected in parallel. The system includescontrol circuitry configured to generate timing signals which controlthe operational state changes of the parallel inverters, such that alloperating parallel inverters may maintain synchronous operation. Thepresent technique also includes a conductor, such as a fiber optic cablecoupled to the control circuitry for conveying the signals from thecontrol circuitry to an inverter. For example, the signals conveyed fromthe control circuitry may have embedded data and clocking informationwhich is transmitted from the control circuitry. Power layer circuitryof each inverter is coupled to a respective data conductor and isconfigured to receive the signals and to compute the timing of the statechanges based upon the received signals. A plurality of solid stateswitches is coupled to the power layer circuitry of each inverter andconfigured to change state to convert input power to controlled outputpower based upon the recomputed timing signals. The power layercircuitry of each inverter is further configured to compute feedbackinformation corresponding to data acquisition, and this feedbackinformation is transmitted back to the control circuitry.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a diagrammatical representation of a motor drive system inaccordance with certain aspects of the present disclosure;

FIG. 2 is further diagrammatical representation of a portion of thesystem of FIG. 1 illustrating power layer interface circuitry used inthe multiple parallel motor drives;

FIG. 3 is a diagrammatical representation of certain functional circuitsand data exchange devices for communicating between control circuitryand power circuitry in accordance with aspects of the present technique;

FIG. 4 is a schematic view of power electronics switches within onephase of an inverter;

FIG. 5 is a diagrammatical view of the interchange of data betweencontrol circuitry and power layer circuitry;

FIG. 6 is a timing diagram illustrating the recreation of gate drivesignals within the power circuitry of individual inverters in accordancewith aspects of the present techniques;

FIG. 7 is a graphical representation of clock recovery within the powercircuitry following the signal timing illustrated in FIG. 6;

FIG. 8 is a block diagram illustrating exemplary logic for coordinatingoperation of the power circuitry in parallel drives;

FIG. 9 is a diagrammatical representation of an alternative embodimentin which a clock signal conductor is provided for transmitting a clocksignal;

FIG. 10 is a diagrammatical representation of operational modes of themotor drive system;

FIG. 11 is a flow chart of a communications protocol between controlcircuitry and the power layer interface circuitry of the multipleparallel motor drives;

FIG. 12 is a series of timing diagrams representing data exchanges fordifferent operational modes with respect to a control event signal;

FIG. 13 is a series of timing diagrams representing a method of clockrecovery which maintains synchronous data transfer; and

FIG. 14 is a series of timing diagrams comparing oscillator drifts whichare corrected to maintain synchronous data transfer.

DETAILED DESCRIPTION

FIG. 1 represents a drive system 10 in accordance with aspects of thepresent disclosure. The drive system is configured to be coupled to asource of AC power, such as the power grid, as indicated by referencenumeral 12, and to deliver conditioned power to a motor 14 or any othersuitable load. The system 10 comprises a plurality of individual drivescoupled to one another in parallel to provide power to the load. In theexample illustrated in FIG. 1, for example, a first drive 16 isillustrated as coupled to a second drive 18 and a further drive 20 whichmay be the third, fourth, fifth or any suitable terminally numbereddrive. A presently contemplated embodiment may accommodate up to 5parallel drives, although fewer or more may be configured in the sameway. It should be noted that certain aspects of the techniques describedherein may be used with a single drive. However, other aspects areparticularly well-suited for multiple parallel drives.

A controller 22 is coupled to the circuitry of each drive and isconfigured to control operation of the circuitry as described more fullybelow. In a presently contemplated embodiment, the controller may behoused in one of the drives or in a separate enclosure. Appropriatecabling (e.g., fiber optic cabling) is provided to communicate controland feedback signals between the controller and the circuitry of theindividual drives. The controller will coordinate operation of thedrives to ensure that the provision of power is shared and thatoperation of the drives is synchronized sufficiently to provide thedesired power output to the motor. In the embodiment illustrated in FIG.1, power filtering circuitry 24 may be provided upstream of the motordrives. Such circuitry may be provided upstream of a line-side bus 26 orsimilar circuitry may be provided downstream of the bus in each of thedrives. Such circuitry may include inductors, capacitors, circuitbreakers, fuses, and so forth that are generally conventional in designand application.

The power bus 26 distributes three phases of AC power between theindividual drives. Downstream of this bus, each drive includes convertercircuitry 28 that converts the three phases of AC power to DC power thatis applied to a DC bus 30. The converter circuitry 28 may be passive oractive. That is, in a presently contemplated embodiment non-gate drivencircuitry alone is used to define a full wave rectifier that convertsthe incoming AC power to DC power that is applied to the bus. In otherembodiments the converter circuitry 28 may be active or gate driven,including controlled power electronic switches that are switched betweenconducting and non-conducting states to control the characteristics ofthe DC power applied to the bus.

Continuing with the components of each drive, bus filtering circuitry 34may be provided that conditions the DC power conveyed along the DCbusses 30. Such filtering circuitry may include, for example,capacitors, inductors (e.g., chokes), braking resistors, and so forth.In some embodiments common devices may be provided on the DC busses,which may be coupled to one another by links illustrated by referencenumeral 32.

Each drive further includes inverter circuitry 36. As will beappreciated by those skilled in the art, such circuitry will typicallyinclude sets of power electronic switches, such as insulated gatebipolar transistors (IGBTs) and diodes arranged to allow for convertingthe DC power from the bus to controlled frequency AC output waveforms.The inverters thus create three phases of controlled frequency output,with each phase being shorted or combined along an output bus 38. Thecombined power may be applied to output filtration circuitry 40, whichmay include magnetic components that couple the output power between thephases. Such circuitry may also be provided along the load-side bus 38.

The controller 22 will typically include control circuitry 42 that isconfigured to implement various control regimes by properly signalingthe inverter circuitry (and, where appropriate, the converter circuitry)to control the power electronic switches within these circuits. Thecontrol circuitry 42 may, for example, include any suitable processor,such as a microprocessor, field programmable gate array (FPGA), memorycircuitry, supporting power supplies, and so forth. In motor driveapplications, the control circuitry may be configured to implementvarious desired control regimes, such as for speed regulation, torquecontrol, vector control, start-up regimes, and so forth. In theembodiment illustrated in FIG. 1, various functional circuit boards 44are linked to the control circuitry and may be provided for specificfunctions. For example, a wide range of options may be implemented bythe use of such circuitry, including the control regimes mentionedabove, as well as various communications options, safety options, and soforth.

The controller will typically allow for connection to an operatorinterface, which may be local at the controller and/or remote from it.In a presently contemplated embodiment, for example, an operatorinterface 46 may be physically positioned on the controller butremovable for hand-held interfacing. The interface circuitry (e.g.,portable computers) may also be coupled permanently or occasionally tothe controller, such as via Internet cabling, or other networkprotocols, including standard industrial control protocols. Finally, thecontroller may be coupled to various remote monitoring and controlcircuitry as indicated by reference numeral 48. Such circuitry mayinclude monitoring stations, control stations, control rooms, remoteprogramming stations, and so forth. It should be noted that suchcircuitry may also include other drives, such that the operation of thesystem 10 may be coordinated, where desired, with that of otherequipment. Such coordination is particularly useful in automationsettings where a large number of operations are performed in acoordinated manner. Thus, the control circuitry 42 may form its controlin coordination with logic implemented by automation controllers,separate computers, and so forth.

FIG. 2 illustrates certain of the components that may be included withinthe individual drives described above. For example, the controlcircuitry 42 is illustrated as being coupled to power layer interfacecircuitry 50. Such circuitry will be provided in each drive and willoperate independently within the drive, but in a coordinated mannerunder the control of the control circuitry. The power layer interfacecircuitry may include a range of circuits, such as a dedicatedprocessor, memory, and so forth. In a presently contemplated embodiment,the power layer interface circuitry 50 includes an FPGA that implementsprogramming for carrying out control of the power electronic switcheswithin the individual drive. The power layer interface circuitry thuscommunicates with the power layer as indicated by reference numeral 52,which is itself comprised of sets of power electronic devices, such asIGBTs and diodes. These switches are illustrated generally by referencenumeral 54. In a typical arrangement, the switches may be provided on asingle support or on multiple supports. For example, in a presentlycontemplated embodiment separate supports are provided for each phase ofpower, with multiple IGBTs and diodes being provided on each support.These devices themselves may be constructed in any suitable manner, suchas direct bond copper stacks, lead frame packages, and so forth. Ingeneral, one or several types of feedback will be provided in thecircuitry as indicated by reference numeral 56. Such feedback mayinclude, for example, output voltages, output currents, temperatures,and so forth. Other feedback signals may be provided throughout thesystem, such as to allow the control circuitry to monitor the electricalparameters of the incoming power, the outgoing power, the DC bus power,and so forth.

The structure and operation of the control circuitry may besubstantially similar to those described in U.S. published patentapplication no. 20100123422, entitled “Motor Controller withDeterministic Synchronous Interrupt having Multiple Serial InterfaceBackplane,” filed by Campbell et al. on Nov. 17, 2008, which is herebyincorporated into the present disclosure by reference.

FIG. 3 illustrates an exemplary manner in which certain functionalcomponents of the individual drives may be coupled to providecoordinated operation of the drives within the system. As shown in FIG.3, the control circuitry 42 is coupled to the inverter circuitry 36 bythe intermediary of optical interfaces. As indicated above, the controlcircuitry will include any suitable processing circuitry, such as anFPGA 58 in the embodiment illustrated in FIG. 3. This FPGA may includeits own memory or separate memory may be provided (not shown). As alsomentioned above, the FPGA 58 may perform various functions incooperation with various function boards as indicated by referencenumeral 60. The FPGA 58 communicates with the various inverters 36 by afiber optic interface 62 which communicates with a mating fiber opticinterface 64. This interface distributes signals to series of fiberoptics interfaces 66 for the individual drives. These components, inturn, communicate with a fiber optic interface 68 at the power level ofeach inverter. The fiber optic interfaces 64, 66, and 68 in each of thecontrol circuitry 42, interface circuitry 50, and inverter circuitry 36,respectively, may each include a pair of receiving (RX) and transmitting(TX) fiber transceivers. The transceivers at each interface 64, 66, and68 may be configured to transmit and/or receive encoded signalscontaining both data and clock information (e.g., Manchester Encodedsignals).

The circuitry at the power level will typically include a further FPGA70 which may be provided on a common support (e.g., circuit board) witha power circuit interface 72. The support, which may be the presentcontext termed the power layer interface, serves to receive signals fromthe control circuitry, to report signals (e.g., feedback signals) backto the control circuitry, to generate drive signals for the powerelectronic switches, and so forth. The circuitry may also performcertain functions to maintain the parallel operation of multipleconnected inverters 36, such as to transmit a synchronizing signal toeach of parallel inverters 36. The power circuit interface 72 mayconvert control signals to drive signals for driving the power circuitryas indicated generally by reference numeral 74. The power circuitry 74will include the power electronic switches as described above.

It should be noted that in certain embodiments signal transmissionbetween the control circuitry and the power layer circuitry may beperformed over conductors other than optical fibers. For example,conventional copper or other conductors may be utilized. In such cases,the fiber optic interface discussed in connection with FIG. 3 may beomitted, and the control circuitry coupled directly to the power layercircuitry.

The particular functions of the power layer circuitry in the presentcontext include the synchronization of communications between thecontrol circuitry 42 and each of the parallel inverters 36. The controlcircuitry 42 communicates differently with the inverters 36 depending onthe operational mode of the system 20. For example, the controlcircuitry 42 may place the inverters in an off mode, an initializingmode, or an active mode. In each of these modes, different signals maybe transceived at the control circuitry 42 and/or the inverters 36.Thus, present techniques include the synchronization of communicationsin different operational modes of the system 20.

Different operational modes and different functions of the power layercircuitry involve the generation of gate drive signals based uponsignals provided by the control circuitry 42. That is, rather thanproviding gate drive signals directly from the control circuitry 42, thecircuitry described herein allows for certain data to be provided to thepower layers of each drive, and based upon a clock running for the FPGAin the power layer circuitry, timing signals can be generated orcomputed in parallel within each power layer. The timing signals serveto generate gate drive signals for the power electronic devices whichwill typically be arranged as illustrated in FIG. 4. That is, each phaseof each inverter will include sets of switches as indicated by referencenumeral 76, notably a high-side switch 78 and low-side switch 80. Thesepower switches are coupled across the DC bus 30 and an output 82 iscoupled between the high and low-side switches. The coordinatedswitching of the switches between conducting and non-conducting statesallows for generation of a controlled output waveform on the output line82. In practice, a number of such switches may be provided on a commonsupport and coupled to one another to provide the desired powercapacity.

FIG. 5 is a diagrammatical representation of the topology of theparallel drives and of the communications between the drivescontemplated for establishing the gate drive signals for the powerelectronic devices at the power layer. In particular, the controlcircuitry FPGA 58 will provide certain data along a first, transmitting(TX) optical fiber and receive data via a second, parallel receiving(RX) optical fiber. A similar optical fiber pair indicated by referencenumerals 84, 86 and 88 is provided for each inverter. The optical fiberpair transmits data and receives data in parallel for each of theinverters, such that the power layer interface circuitry within each ofthe inverters, and in particular the processor associated with thiscircuitry can recompute clock or timing information from the controlcircuitry FPGA without the need for the clock data being transmitted tothe inverters. In a presently contemplated embodiment the lengths 90 ofthese optical pairs are substantially equal to reduce differencesperformance due to the propagation of the signals between the controlcircuitry and the power layer circuitry.

As will be appreciated by those skilled in the art, because the outputsof the inverters are essentially shorted, differences in switching andswitch timing between the power layers of each inverter can causecirculating currents that are generally to be avoided. The arrangementillustrated in FIG. 5 and described in greater detail below allows formaintaining tight tolerances in the switching timing between theinverters, such as on the order of 20-40 ns. In a presently contemplatedembodiment, data sent from the control board FPGA to the power layers ofeach inverter include a control status, a carrier wave increment, adeadtime value, and U, V, and W (output) phase compare values. Dataprovided by each power layer back to the control board FPGA includes thebus voltage, temperature, a fault status, and U, V, and W phasecurrents. As described below, based upon the information provided toeach power layer, gate drive signals may be generated in parallel thatare inherently synchronized without the overhead of transmitting a clocksignal. That is, the FPGA of each power layer, operating in accordancewith its own oscillator and clock, can accurately generate or recomputedtiming for gate drive signals for the switches of the individualinverter in synchronicity with those of the other inverters. Asdescribed in greater detail with reference to FIGS. 6 and 7, thecircuitry works, in a presently contemplated embodiment, by transferringdata for synchronization that is imbedded in the data provided along thetransmitting optical cable. This data allows for clock data recovery atthe power layer. Moreover, a carrier waveform signal is sent from thecontrol circuitry that facilitates the clock data recovery. Finally, aphase comparison is performed by each power layer that, in conjunctionwith the recovered clock data allows for synchronization of the gatedrive signals.

In operation, the control circuitry sends signals to the power layercircuitry of each inverter that permits the power layer circuitry tocompute or recompute timing for changing the conductive state of solidstate switches in each of the respective inverters. In a presentlycontemplated embodiment, the computations are based upon reconstructionof a carrier waveform by reference to a recovered clock step and atriangle waveform accumulator. To permit computation or recomputation ofthe timing, the control circuitry sends a triangle increment signal thatallows for reconstruction of the carrier triangle waveform. It alsosends compare values for each of the three output phases U, V, and W.Deadtime or delay signals are also sent to allow for avoiding placinghigh and low switches of each inverter leg in conducting states at thesame time (e.g., FIG. 3).

FIG. 6 represents exemplary timing diagrams for high and low sideswitches of the type illustrated in FIG. 3 for each inverter leg. Itshould be noted that such switching is performed for the identical legsof the parallel inverters, and similar switching is performed, althoughphase shifted, for the other legs of the inverters. It should also benoted that the processes described below are performed at the powerlayer, unlike existing topologies that may perform similar processingfor generating of gate drive timing at the level of the controlcircuitry. Certain aspects of the computations themselves may besubstantially similar to those described in U.S. Pat. No. 5,917,721,entitled “Apparatus for Reducing the Effects of Turn on Delay Errors inMotor Control” and issued to Kerkman et al. on Jun. 29, 1999; U.S. Pat.No. 5,990,658, entitled “Apparatus for Controlling Reflected Voltage onMotor Supply Lines” and issued to Kerkman et al. on Nov. 23, 1999; andU.S. Pat. No. 7,738,267, entitled “Systems and Methods for Common-modeVoltage Reduction in AC Drives” and issued to Tallam et al. on Jun. 15,2010; and U.S. Pat. No. 7,342,380, entitled “System and Method forAdjustable Carrier Waveform Generator” and issued to Kerkman et al. onMar. 11, 2008, all of which are hereby incorporated into the presentdisclosure by reference.

As shown in FIG. 6, a triangular carrier wave 92 is recomputed in eachof the power layer interface circuits based upon information receivedfrom the control circuitry. The rate of change or slope of thetriangular carrier waveforms depends upon the step increment for thewaveform and a recovered clock signal. Recomputation of the carrier wavesignal is discussed below with reference to FIG. 7. The triangularcarrier wave is crossed by a phase count line as indicated by referencenumeral 94 in FIG. 6. This phase count line allows for the duty cycle ofthe solid state switches to be altered as it is raised or lowered tochange its points of intersection with the carrier wave. Shifting of thevertical location of the phase count 94 is provided by the phase comparevalues transmitted from the control circuitry to the power layerinterface circuitry. The points of intersection lead to computation ofphase comparator outputs as indicated by reference numerals 96 in FIG.6. In FIG. 6, the timing of the upper solid state switch in a pair isillustrated in the upper portion of the diagram, where as timing for alower solid state switch in a pair is indicated in the lower section ofthe diagram. It should be noted that for both the upper switch and thelower switch, the comparator output 96 is generally identical butinverted. The intersections of the phase count line and the carrier waveproduce rising edges 98 and falling edges 100 in each of thesecomparator outputs at times 102 and 104, with the rises and falls in theupper and lower switches being opposite to one another.

In the embodiment illustrated in FIG. 6, moreover, deadtimes or delaysare taken into account in conjunction with the phase comparator outputto produce upper switch drive timing and lower switch drive timing,indicated by reference numerals 106 and 108, respectively. That is, thecontrol circuitry transmits a deadtime or delay signal to the powerlayer circuitry that causes the OFF or non-conducting period of theupper and lower switches to be extended and the ON or conducting periodto be reduced, thereby avoiding placing both switches in a conductivestate simultaneously, a condition that could lead to “shoot-through” ofcurrent. This delay, indicated in FIG. 6 by reference numeral 110,results in the computed timing providing for periods in which theswitches are in conducting and non-conducting states to produce pulsewidth modulated signals that are applied to the gates of the solid stateswitches. That is, as shown in FIG. 6, period 112 represents the periodin which the upper switch is conducting, while reference numeral 114represents the period in which the lower solid state switch isnon-conducting. It may be noted that the deadtime allows for the upperswitch to be placed in a non-conducting state before the lower switch isshifted to a conducting state. Reference numeral 116, then, representsthe period in which the upper solid state switch is a non-conductingstate, while reference numeral 118 represents the period in which thelower solid state switch is in a conducting state. Here again, thedeadtime allows for avoiding both switches conducting at the same time.These timing signals are then applied to gates to control theenergization of the solid state switches in a conventional manner. Itshould be noted, however, that if the deadtime does not change, thevalue used for this parameter may be sent less often or uponinitialization of the circuitry, and need not be sent repeatedly by thecontrol circuitry. Moreover, if the deadtime is fixed, some embodimentsmay simply store the deadtime value in the power layer circuitry.

FIG. 7 represents an exemplary technique for recomputing the trianglewaveform through the use of an accumulator in the power layer interfacecircuitry. The diagram of FIG. 7 illustrates a carrier waveform counter120 that would correspond to the carrier wave 92 of FIG. 6. The counterwaveform is illustrated as defined by an accumulator value 122 and arecovered clock time 124. The clock time is divided into time increments126 and the carrier counter is then computed based upon an accumulatedtime step 128. The triangle increment for this carrier counter istransmitted from the control circuitry to the power layer circuitry ofeach inverter.

It should be noted that the signals transmitted from the controlcircuitry to the power layer circuitry of each inverter are sufficientto recompute the carrier wave and the timing signals, thus allowing eachinverter, independently and in parallel, to recompute the timing signalswith high fidelity. In a presently contemplated embodiment, for example,deviations between timing of the inverters do not exceed approximately40 ns, and in certain embodiments may not exceed approximately 20 ns.Synchronization pulses may be sent periodically from the controlcircuitry to the power layer interface circuitry to re-establishsynchronicity between the clocks. That is, in the event that theoscillators of the processors for the power layer interface circuitry donot operate at the same rates, any variation may be periodically (e.g.,every 250 μs) corrected by the use of synchronization pulses.Nevertheless, the ability to recompute the timing signals at the powerlayer circuitry enables paralleling of the inverters while significantlyreducing circulating currents.

FIG. 8 represents exemplary logic for carrying out these operations. Thelogic, designated generally by reference numeral 130 in FIG. 8, beginswith generating reference data in the control circuitry, as indicated bystep 132. This reference data will typically include the timing or datathat can be used to compute the timing, including, in a presentembodiment, the carrier triangle waveform increment, U, V, and W phasecompare values, and a deadtime or delay value. As indicated at step 134,then, these values are transmitted in parallel to the inverters, andparticularly to the power layer interface circuitry. As indicated atstep 136, the clock timing is recovered in the inverters as indicated inFIG. 7, based upon the clock interval of the power layer interfacecircuitry and the triangle increments. At step 138, then, the timingsignals are reconstructed in the power layer interface circuitry andpulse with modulated signals are generated for driving the solid stateswitches of each of the inverters. At step 140, signals may be sent fromeach inverter back to the control circuitry. As noted above, in apresently contemplated embodiment, such information may include U, V,and W phase currents, bus voltages, temperatures, false status, and soforth.

As noted above, the foregoing process allows for accuratesynchronization of switching of parallel-coupled inverters having acommon control circuit in common three-phase output. The waveform, ordata used to recompute the waveform, is generated by the controlcircuitry FPGA and is mirrored by identical waveforms in the power layerFPGAs. Such recomputation of the timing signals facilitates control taskinterrupt generation simplifies transmission of information between thecontrol circuitry and the power layer circuitry, and allows fordrive-to-drive synchronization (e.g., via IEEE-1588) where desired. Suchdrive-to-drive synchronization may be performed as disclosed in U.S.published patent application no. 20100123425, entitled “Motor DriveSynchronization System and Method,” and filed by Campbell et al. on Nov.17, 2008, which is hereby incorporated into the present disclosure byreference.

In certain embodiments, it is also contemplated that a further opticalconductor may be provided between the control circuitry and each powerlayer interface over which a clock signal could be transmitted. FIG. 9illustrates diagrammatically a system of this type. As discussed above,each inverter 36 may be coupled to the control circuitry via parallelserial cables which include a pair of optical fibers. A third opticalfiber 144 could be provided over which a clock signal is provided toeach power layer interface from the control circuitry. The provision ofthis clock signal may obviate the need for clock recovery throughrecomputation of the triangular waveform as illustrated in FIG. 7. Therecomputation of the timing signals could, thus, be performed insynchronicity based upon the transmitted clock signals.

As noted above, the common control circuitry allows for synchronizingparallel inverters 36 for different modes of operations (i.e., changingthe conductive state of IGBT's in a coordinated fashion). Thecommunications between the control circuitry 42 and the inverters 36generally described above may differ depending on a mode of operation ofthe system 20. For example, the control circuitry 42 may request theinverters 36 to operate in three general modes of operation, includingan off mode, an initializing mode, and an active mode. FIG. 10illustrates an operational state machine of the system 20, whichincludes the three modes of operation. During the active mode 150, thecontrol circuitry 42 may send signals including data, clock information,and synchronization pulses, through a fiber optic pair 84 to the powerlayer circuitry of each inverter 36. Timing information may be computedto generate gate drive signals in the inverter 36, according thetechniques described above. The control circuitry 42 may shut down theswitching of the inverters 36 by sending a power down signal 152 tochange to a state of the system into an off mode 154. The off mode 154may be the default mode where inverter switches 54 are reset to adefault state (typically non-conducting). In some embodiments, powerdown data may be transmitted from the inverters 36 to the controlcircuitry 42 during the off mode 154. Such power down data may include,for example, information regarding the power cycle of the previousactive mode, system register information, or data corresponding to theelapsed life of system components during the previous active mode (e.g.,motor bearing, machine bearing, fans, buses, etc.).

Before the inverters 36 return to an active mode 150 from an off mode154, the inverters 36 generally enter an initializing mode 158. Thestate may change 156 to an initializing mode 158 after the controlcircuitry 42 has received the power down data from the inverter 36.During the initializing mode 158, the control circuitry 42 and theinverters 36 may exchange information corresponding to identification,revision, and manufacturing data, or any other data used to define theparticular inverter 36 that is connected to the control circuitry 42.The state may change 160 once the information is received at the controlcircuitry 42, and the system 20 may once again operate in an active mode150.

In each of the operational modes, FIG. 11 provides a flow chart whichgenerally summarizes the communications protocol 162 between the controlcircuitry 42 and the inverter 36 for different modes of operation. Thecontrol circuitry 42 transmits a control event signal 164 which in apresently contemplated embodiment includes a Manchester encoded signalwith embedded data and clock information. Manchester encoded signals aregenerally transmitted as a data bit stream with no DC component. A clocksignal can be recovered from the signal by, for example, the FPGA 70 ofthe power layer circuitry of each inverter 36. At the rising edge 166 ofthe signal, a synchronization pulse 168 may be transmitted to insurethat each of the parallel inverters 36 is synchronized with others. Atthe falling edge 170 of the signal, data exchange 172 may occur. Duringdata exchange 172, different types of data may be transmitted andreceived between the control circuitry 42 and each parallel inverter 36,depending on the mode of operation (e.g., offline mode 154, initiatingmode 158, active mode 150) in which the system 20 is operating. Thedifferent types of data exchanged will be further discussed with respectto FIG. 12.

Data exchange may occur until all data is exchanged. The controlcircuitry 42 may measure (block 174) a halt period of the data exchange.A halt period refers to a period of time in which no clock signals areoutput, which may indicate that data exchange is complete for thecurrent operation. The control circuitry 42 may determine (block 176)whether the halt period exceeds a timeout duration. If the halt perioddoes not exceed a threshold timeout duration, the control circuitry 42may continue to measure the halt period and maintain the currentoperation. If the halt period exceeds a threshold timeout period, astate change 178 may occur. For example, the system 20 may change froman offline mode 154 to an initiating mode 158, from an initiating mode158 into an active mode 150, or from an active mode 150 into an offlinemode 154.

A more detailed description of synchronized operation in the threedifferent operational modes is provided in the timing diagrams of FIG.12. Specifically, FIG. 12 illustrates data exchange which is transmittedfrom or received at the control circuitry 42 with respect to a controlevent signal 164 generated at the control circuitry 42. Beginning firstwith the offline mode 154, the control circuitry 42 may be configured toreceive off mode signals 186 and transmit off mode signals 188. Beforethe rising edge 166 of the control event signal 164, the controlcircuitry 42 may transmit a synchronization pulse 168. Thesynchronization pulse 168 is transmitted to all parallel inverters 36 tosynchronize all parallel inverters 36 with respect to each other. Thecontrol circuitry 42 may not receive or transmit (as indicated by theidle periods 180) until the falling edge 170 of the control event signal164. After the falling edge 170 of the control event signal 164, thecontrol circuitry may simultaneously transmit and receive power downdata 182 and power up data 184. The power down and power up data 182 and184 may include information corresponding to the power cycle of theprevious active mode, system register information, or data correspondingto the elapsed life of system components during the previous active mode(e.g., motor bearing, machine bearing, fans, buses, etc.). Suchinformation may be used such that the control circuitry 42 canaccumulate data before a subsequent power down into the off mode 154. Asufficiently long idle period 180 following the completion of the powerup and power down 182 and 184 data transfer may result in a change ofstate into the initializing mode 158.

In the initializing mode 158, the control circuitry 42 may by configuredto receive initializing mode signals 190 and transmit initializing modesignals 192. Before the rising edge 166 of the control event signal 164,the control circuitry 42 may transmit a synchronization pulse 168 andmay not receive or transmit (as indicated by the idle periods 180) untilthe falling edge 170 of the control event signal 164. After the fallingedge 170 of the control event signal 164, the control circuitry maytransmit thermal parameter data 198 to the parallel inverters 36. Thethermal parameter data 198 may include parameters used by a thermalmanager in the control circuitry 42 which controls the temperature ofthe inverters 36 for various modes of operation. For example, during aninitializing mode 158, the thermal parameter data 198 may set theinverters 36 to a temperature suitable for transmitting identificationdata, which may include system status information, identificationnumber, and manufacturing information such as assembly number orrevision, serial number, date, etc. The identification data 200 may bereceived at the control circuitry 42. A sufficiently long idle period180 following the completion of the identification data 200 received atthe control circuitry 42 may result in a change of state into the activemode 150.

In the active mode 150, the control circuitry 42 may by configured toreceive active mode signals 194 and transmit active mode signals 196.Before the rising edge 166 of the control event signal 164, the controlcircuitry 42 may transmit a synchronization pulse 168 to the power layercircuitry of each of the parallel inverters 36. In response to thesynchronization pulse 168, the inverters 36 may compute feedback data204 associated with data acquisition in the active mode. The feedbackdata 204 may include information regarding the bus voltage and thecurrent values at each of the three phases of the parallel inverters 36.Such feedback information may indicate to the control circuitry 42whether the inverters 36 can properly accept data in the active mode150. In some embodiments, the falling edge 170 of the control eventsignal 164 may occur approximately 6 μs following the rising edge 166 ineach sync cycle. The feedback data 204 may be transmitted from theinverters 36 to the control circuitry 42 within the 6 μs interval. In apresent embodiment, the individual power layers acknowledge reception ofthe data from the control circuitry. If all power layers acknowledgereception, then a followup message (“use PWM data”) is sent to all powerlayers. If that message is not received by each of the power layercircuitry, then all power layers utilize the previous control data forcontrolling their respective switches.

The control circuitry 42 may not transmit (as indicated by the idleperiods 180) until the falling edge 170 of the control event signal 164.After the falling edge 170 of the control event signal 164, the controlcircuitry may transmit thermal parameter data 198 to the parallelinverters 36. Such thermal parameter data 198 transmitted in the activemode 150 may control the temperature of the inverters 36 to a suitabletemperature for active mode operation 150. The inverters may returnthermal feedback data 206 in response to the thermal parameter data 198transmitted by the control circuitry 42 and received at the inverters36. The thermal feedback data 206 received at the control circuitry 42may indicate that the inverters 36 are prepared to receive control data202. The control data 202 may include pulse width modulated data whichmay be addressed to the U, V, and W phases of each inverter 36. Further,the control data may have embedded clock signals in the form of thepreviously discussed triangular carrier waves which may be used torecompute timing at each inverter 36. In some embodiments, the inverters36 may transmit an acknowledge signal 204 to the control circuitry 42.The acknowledge signal 204 may indicate that the control data 202 wasreceived correctly at the inverter 36. Receiving the acknowledge signal204 from all parallel inverters 36 may insure that all inverters 36accurately received the same control data 202. In one embodiment, if oneinverter 36 does not acknowledge that valid data 202 was received, thecontrol circuitry 42 may use the same data in the next synchronizationframe for all parallel inverters 36, thus maintaining synchronousoperation of the parallel inverters 36. A sufficiently long idle period180 following the completion of the transmitted control data 202 and/orthe acknowledge signal 208 may result in a change of state into theactive mode 150.

It should be noted that the timing diagrams illustrated in FIG. 12 haveapproximate time durations for all represented events. The timingdiagram serves only to illustrate when data transfers approximatelyoccur with respect to the control event signal 164. For differentfunctions in each mode of operation, data transfers may take differentamounts of time. Furthermore, in some embodiments, additionaloperational modes may exist. Additionally, while idle periods 180 areindicated throughout the diagrams corresponding to each operationalmode, in some embodiments, such idle periods may not be necessary inactual operation and serve only to separate different data transferevents for the purpose of explanation.

As discussed above, a synchronization pulse 168 is transmitted to thepower layer circuitry of each of the parallel inverters 36 approximatelyevery 250 μs to synchronize the operation and data transfer for each ofthe parallel inverters 36. Due to the parallel operation of multipleinverters 36 and the high data stream rate of approximately 66 MHz,drifts or differences in pulse frequencies from oscillators in theprocessing circuitry of the power layer circuitry may cause, over time,a loss of synchronicity between synchronization pulses. For example, thefrequency of the recovered clock signals may be slightly differentbetween the control circuitry 42 and the power layer circuitry of eachinverter 36. Furthermore, with parallel inverters 36 in the system 20,asynchronous clock recovery is even more likely to occur, particularlywhen variability is present in the frequency of the processing circuitryoscillators. Uncorrected asynchronous clock recovery, even betweensynchronization pulses occurring at a 250 μs interval, may result inerrors in the operation of one or more inverters 36 which may eventuallyaffect the performance of the entire system 20 (e.g, by causingcirculating currents).

Therefore, the present embodiments also address the synchronization ofclock recovery at the power layer circuitry of each parallel inverter 36during data transfer between the synchronization pulses 168. In apresent embodiment, a data stream rate of approximately 66 MHz is usedfor the power layer clocks, and the synchronization of data transferbetween synchronization pulses 168 may utilize an approach, includingManchester encoding, for example, which allows a comparativelydeterministic sampling of the data stream transmitted by the controlcircuitry. The sampling of the transmitted data may be used to adjustfor drift or frequency differences in the oscillation rates within eachpower layer circuit, allowing for correction recovered clock timing. Oneor more embodiments of such an approach are explained in FIGS. 13 and14.

FIG. 13 illustrates several timing diagrams which explain an embodimentfor adjusting for oscillator rates in synchronizing clock recovery atthe power layer circuitry of each inverter 36. The data stream 198represents the data transferred from the control circuitry 42 to thepower layer circuitry of each inverter 36. As discussed above, the datastream 198 may be Manchester encoded, resulting in the Manchesterencoded stream 200. The Manchester encoded stream 200 may have twice therate of the serial data stream 198 owing to the division of the data byinsertion of mid-bit. For example, the Manchester encoded stream mayhave a frequency of approximately 133 MHz, such that two data bits(referred to as Manchester bits) are transmitted in the Manchesterencoded stream 200 for every data bit in the serial data stream 198. TheManchester encoded stream 200 may therefore have a transition in themiddle of each data bit, which increases the detectability of the edgesof each data bit for improved clock recovery by the power layercircuitry.

The power layer circuitry of each inverter 36 includes an oscillatorconfigured to produce a signal for sampling the received Manchesterencoded stream 200. In a present embodiment, the oscillator may have afrequency of approximately 200 MHz, as indicated by the sampling clocksignal 200. In practice, FPGA logic may limit the frequency of thesampling clock signal, and although faster oscillators may be used, suchdevices may be increasingly costly as the oscillator frequency isincreased. However, in some embodiments, higher sampling rates may beobtained by phase shifting the sampling clock signal 200, and quadraturesampling by using both rising and falling edges of both pulse trains.All such sample triggers are then used to sample concurrently,effectively quadrupling the sampling frequency (based on 4 edges percycle). The oscillator may input the sampling clock signal 200 intocircuitry configured to shift the phase of the sampling clock signal 200by 90°. In the illustrated embodiment, this phase shifted sampling clocksignal 202 is used concurrently with the sampling clock signal 200,along with quadrature sampling to provide an effective sampling rate of800 MHz and thereby to retrieve 12 samples of each data bit (at 1.25 nsin a 15 ns interval), as represented by the samples 206. The samples 206correspond with either a rising edge or a falling edge of either thesampling clock signal 200 or the phase shifted sampling clock signal202. Although the 12 sampled bits (referred to as sample bits)correspond with the size of one data bit in the serial data stream 198provided in this example, different sample sizes, oscillatorfrequencies, clock frequencies and sample rates may also be used inother embodiments.

The recovered data stream at the power layer circuitry of each parallelinverter 36 is represented in the recovered data stream 208. To maintainsynchronous clock and data recovery, the power layer circuitry mayimplement a transition register 210 which may include a 0 or a 1 foreach sample bit of each data bit. As illustrated, the transitionregister 210 for the 12 bit sampling method currently described may have12 sample bits of 0 s and 1 s, with each 1 representing an edge of aManchester bit in the Manchester encoded stream 200. Circuitry in thepower layer of each parallel inverter 36 may track the position of asample bit (e.g., the Manchester encoding mid-bit) to verify that theposition of the sample bit does not drift, which may indicate a driftingof the oscillator. In general, if no drifting is taking place, the bitshould occur in the same position in the sampling register for eachcycle. If the oscillator frequency is faster or slower than the designfrequency, the position of the monitored bit may move (e.g., occur moreor less frequently in an 11^(th) or 13^(th) position, rather than a12^(th) for a sampling rate of 12 per cycle). For example, asillustrated in the transition register 210, if the oscillator isoperations precisely as shown (which is not likely), the second 1 isalways occur in the same position within each bit. A further 1 wouldthen be expected 12 sample bit positions from the first 1, assumingagain 12 samples per bit. Drifting of the second 1, as will be furtherexplained with respect to FIG. 14, may indicate that the oscillator atthe power layer circuitry of the particular inverter 36 is operatingasynchronously. That is, if the oscillator has a frequency other thanthe design frequency, the differences in the number of samples betweentransition bits will ultimately occur, and at rates that may differdepending upon how differently the oscillator rate differs from thedesign rate.

The power layer circuitry may manage the clock data recovery byutilizing a clock data recovery (CDR) count register 212. By inputting0, 1, or 2 into the CDR count register 212, the power layer circuitrycan set the clock cycle of the recovered clock signal, or the CDR signal214. As illustrated, each rising edge of the CDR signal 214 correspondsto a 0 or reset in the CDR count register 212, and each falling edge ofthe CDR signal 214 corresponds to a 1 in the CDR count register 212. TheCDR count register 212 may use a repeated sequence of 0, 1, and 2 togenerate the CDR signal 214 when no drifting is detected in thetransition register 210. The situation represented by the transitionregister 210, the CDR count register 212, and the CDR signal 214 may bereferred to as synchronous operation 216.

Variation or drifting from the synchronous operation 216 mentioned aboveis represented in the timing diagrams of FIG. 14. Specifically, thetiming diagrams of FIG. 14 illustrate of an oscillator in the powerlayer circuitry of a parallel inverter 36 operating too slowly, asindicated by reference numeral 218 and too fast, as indicated byreference numeral 226. In the case of an oscillator running at a rateslower than the design rate, the position of the transition bits or 1 sdrifts backwards. In the illustration 218, a particularly fast drift isshown, with 13 samples between transitions whereas a design rate wouldcall for 12. In practice, much slower drifts may be expected. That is,as shown in the transition register 220, the position of the 1 s shiftat each bit register, and the position of the second 1 is 13 sample bitsaway from the first 1 (in contrast with the 12 sample bit difference inthe synchronous operation 216 of FIG. 13). The power layer circuitryrecognizes the situation as a drifting of the oscillator, and correctsthe effects of the drift by subtracting a clock cycle. For example, inthe illustrated embodiment, when the number of samples betweentransition bits is detected to be too high, the power layer circuitrymay insert a 3 (an additional cycle count) into the CDR count register222, as indicated by the arrow, out of the regular order to delay therising edge of the CDR signal 224. That is, in this case the oscillatoris detected as sampling at too low a frequency, and an extension oradditional step in the count is used to at least partially correct forthe accumulating difference. In a presently contemplated embodiment, thecorrection is made when comparison of the number of samples betweentransition bits indicates that differences between the number of samplesand the design number have occurred 3 times. This threshold may behigher or lower, however, depending upon the precision desired in thecorrections.

In the event of a drift in the opposite sense, as indicated by referencenumeral 226, the position of the 1 s drift forward in each cycle (hereagain a particularly fast drift is illustrated). As shown in thetransition register 226, the position of the 1 s shift at each bitregister, and the position of the second 1 is 11 sample bits away fromthe first 1 (in contrast with the 12 sample bit difference in thesynchronous operation 216 of FIG. 13). The power layer circuitryrecognizes the situation as a drift to too high a sampling rate of theoscillator, and corrects the effects of the drift by adding a clockcycle. For example, the power layer circuitry may insert a 0 into theCDR count register 230, as indicated by the arrow, out of the regularorder to instruct the rising edge of the CDR signal 232 to be resetsooner than the previous period, thereby at least partially correctingfor the accumulated error. Here again, in the presently contemplatedembodiment, the correction is made when a three errors are detected,although higher or lower thresholds may be used. As in the previouscase, these thresholds may be varied based upon the clock data recoverysource frequency and the accuracy of the clock correction desired.

Therefore, the Manchester encoded signal 200 and the 12 bit sample rateenables the power layer circuitry of each parallel inverter 36 to trackthe position of the data signal edges in a transition register and todetect the position of data signal edges relative to another edge in thesame register bit. Such techniques enable the detection of asynchronousoperation such that the power layer circuitry can appropriately subtractor add a clock cycle (e.g., a 5 ns increment in the present embodiment)to synchronize either a slow drift or a fast drift, respectively. Thesystem thus effectively uses the sampled signals, and particularly thetransitions in the sampled bits, as a reference for detecting andcorrecting for variations in the oscillator frequencies. In theillustrated embodiment the technique has been shown to provide gateswitching differences between inverters (or between the clock rate ofthe control circuitry and any single power layer) of approximately 20 ns(24 ns in a present embodiment), while a difference of approximately 40ns would have been deemed sufficient to avoid circulating currents.

While the foregoing techniques have been described in the context ofparallel inverters, it should be noted that the same techniques could beused when controlling the operation or switching of a single inverter.That is, control circuitry could be adapted for generating timingsignals or data from which timing signals can be derived. Data can besent to a power layer interface for a single inverter that would, asdiscussed above, reconstruct the timing signals for changing the statesof the solid state switches of the single inverter. In certain contexts,this could allow for simplification in product designs, product lines,modular power layers for inverters, modularity in programming of suchcircuitry, and so forth.

It should also be noted that, while particular techniques are disclosedherein for computation or recomputation of the timing signals used fordriving the solid state switches of the inverters, other techniques mayalso be used. That is, information may be transmitted by the controlcircuitry to the power layer circuitry that permits switch timing to beestablished at the power layer circuitry by other algorithms.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A system for controlling operation of apower inverter, comprising: control circuitry configured to generate acontrol event signal for synchronizing events in one or more operationalmodes of the system; a data conductor coupled to the control circuitryfor conveying the signals to and from the control circuitry; power layercircuitry coupled to the data conductor and configured to receive thecontrol event signal and to communicate with the control circuitry viathe data conductor based on the control event signal and based on theoperational mode of the system; and a plurality of solid state switchescoupled to the power layer circuitry and configured to change state toconvert input power to controlled output power based on the controlevent signal and based on the operational mode of the system.
 2. Thesystem of claim 1, wherein the control event signal comprises a synccycle comprising one rising edge and one falling edge approximately 6 μsfollowing the one rising edge.
 3. The system of claim 1, wherein thedata conductor comprises two optical fibers.
 4. The system of claim 3,wherein a first optical fiber is dedicated to transmitting signals fromthe control circuitry to the power layer circuitry, and a second opticalfiber is dedicated to transmitting signals from the power layercircuitry to the control circuitry.
 5. The system of claim 4, whereinthe power layer circuitry transmits, over the second optical fiber, atleast signals representative of power phase current.
 6. The system ofclaim 5, wherein the power layer circuitry also transmits, over thesecond optical fiber, signals representative of at least one oftemperature, bus voltage, and fault status.
 7. The system of claim 4,wherein the one or more operational modes comprises an off mode, andwherein the control circuitry is configured to transmit a sync pulse tothe power layer circuitry and configured to receive power down data fromthe power layer circuitry during the off mode.
 8. The system of claim 4,wherein the one or more operational modes comprises an initializingmode, and wherein the control circuitry is configured to transmit a syncpulse to the power layer circuitry and configured to receiveidentification data from the power layer circuitry during theinitializing mode.
 9. The system of claim 8, wherein the controlcircuitry is further configured to transmit thermal parameter data tothe power layer circuitry during the initializing mode.
 10. The systemof claim 4, wherein the one or more operational modes comprises anactive mode, and wherein the control circuitry transmits a sync pulseand control data to the power layer circuitry during the active mode.11. The system of claim 10, wherein the control circuitry receives anacknowledgement signal from the power layer circuitry following thetransmitted control data during the active mode.
 12. The system of claim10, wherein the control circuitry is further configured to transmitthermal parameter data to the power layer circuitry during the activemode.
 13. The system of claim 12, wherein the power layer circuitry isfurther configured to transmit a thermal feedback signal to the controlcircuitry in response to the thermal parameter data transmitted from thecontrol circuitry.
 14. The system of claim 10, wherein the control datacomprises encoded data and timing information, and wherein the powerlayer circuitry is configured to recompute timing information from thecontrol data to drive the plurality of solid state switches.